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Here is where we are going to show you how to create your very own headphones.

Step 1: Materials

Materials-

  • 1 Whole Roll of 28 Gauge Copper Wire
    • Buy on Amazon for $20.16
  • 2 Plastic Cups
    • Buy at the 99 cent Store for $0.99
  • 2 0.5 inch diameter Neodymium Magnets
    • Amazon for $13.57
  • 1 Roll of Electrical Tape
    • Amazon $1.50
  • 1 0.75 inch diameter Glue Stick (Can be any cylinder object but needs a diameter of 0.75 inches)
    • 99 cent store for $0.99
  • 1 Aux Cord or Plug
    • 99 cent Store for $0.99
  • 1 Roll of Duct Tape (Color of Choosing)
    • 99 cent Store for $0.99
  • 1 Roll of Wax Paper
    • 99 Cent Store for $0.99
  • 1 Hot Glue Gun
    • Amazon for $7.99
  • 10 Hot Glue Gun Sticks
    • Amazon for $6.89 (Has more than 10 sticks)
  • 1 Large Beanie
    • 99 Cent Store for $0.99
  • 1 Pair of Non-Stick Scissors
    • Amazon for $9.97
  • 1 Sheet of Sandpaper
    • 99 Cent Store for $0.99
  • Decorations
    • We used butterflies as our logo

Step 2: The Basket

1. Grab a 2 in. plastic cup, if larger cut it down to 2 inches (You want the bottom part of the cup, so cut off the top part)

2. Use 6 inches of electrical tape and put the tape around the bottom rim

3. Repeat for the other cup

Step 3: The Coil

1. Now you are going to work on the coil, by getting 28 gauge wire, cut about 3.5 feet, and a cylinder object like a gluestick with a diameter of 0.75 inches

2. Leave 5 inches of wire at the end

3. Start wrapping the wire around the gluestick 35 times

4. Sand 2 inches of the end of the wire on both sides

5. Repeat for a second coil

Step 4: The Speaker

1. Lay the cup upside down and lay the magnet in the middle of the cup

2. Put the coil around the magnet

3.Securely tape the coil and magnet down with 4 inches of electrical tape onto the cup (Make sure it's in a X pattern when taping onto the coil and magnet)

4. Repeat for other speaker

Step 5: The Diaphragm

1. Cut 2 squares of wax paper that cover the top of the cup

2. Hot glue one of the squares wax paper onto the the cup

3. Cut excess wax paper that is around the cup.

Step 6: The Beanie

1.Cover cup in your choice of duck tape (another alternative could be masking tape)

2. Measure another wire that fits from one of your ears to the other with at least an 2 inches of extra wire to wrap the ends of the wire together (this will be the shape of the headphones).

4. You will need to sand the end at least 4 inches of the each end of the new wire.

5. Next, carefully connect the new wire to the end of the coil from your headphone.

6.Repeat step 5 with the other headphone

7. You will now want to cover the wire in duct tape or your choice of material.

8. To do this you carefully wrap your material around the thin wire, until it is completely covered (Double check that there is no loose wire)

9. Hot glue the headphones to the inside of the beanie

10. Connect the ends of the wire to the the aux plug

11.Grab one end of the wires and stick it through a hole in the aux plug

12. Securely twist the wire together and make sure it is touching the aux plug

13. Repeat for the other end of wire on the opposite hole

14. Tape loose wires with duct tape (color of choosing)

15. Wear your new fashionable headphones

Step 7: Trouble Shooting

Things to try if your headphones don't work:

  • Make sure the coil is pressed into the cup
    • This is so the vibrations travel better
  • Move the wires around
    • Since they might not be touching , so the current can't flow
  • Check if the ends of the wire are fully sanded
    • For current to flow
  • Double check if the volume is at it's highest setting

Step 8: Explanations

Why these materials?
You need the wire to create the voice coil and a pathway for the current to run through. The plastic cups are for the basket of the speaker. The neodymium magnets create a magnetic field and they are strong and small. The tape and hot glue are for holding the headphones together and decoration. The glue stick for making the voice coil. The aux plug provides current from your device that you are trying to play music from. The wax paper is the diaphragm. You need the beanie so the headphones can stay on your head. The non-stick scissors are for cutting tape and wire, so there is no need for wire cutters. The sandpaper is for sanding the ends of the wires for the current to flow through. This is why you need all these materials.

Why 35 coils?

We chose 35 coils because my group tested 15, 25, and 35 coils and found that 35 coils worked the best and made sound unlike the other coils, since the other coils made no other sound. We would have tested further, but we did not have enough time to keep testing.

What are the 3 main components in a speaker?

The 3 main components of a speaker are the voice coil, the magnet, and diaphram. The voice coil is important because it provides the vibration, which moves the particles and creates sound. The magnet is also important because it provides the magnetic field, which moves the voice coil when there is a current running through it. The last most important part of a speaker is the diaphram because it makes the sound clearer and give the sound a direction to move through giving it a better pathway into your ears.

Why voice coil vibrate?

The voice coil vibrate because the magnet makes a magnetic field and when the current flows into the voice coil. The voice coil switches polarity, the direction of a magnetic field, and when the magnetic and current has the same polarity they repal. Then the polarity switches and they attract to each other, creating the vibration.

How vibrations turn into what we perceive as sound?

The vibrations turn into sound because the voice coil is compressing and depressing. Sound waves have a rarefaction and compression, so the voice coil makes the particles move into sound waves and that is what we hear.

Results from prototyping- How variables affect quality or loudness of sound?

The more voice coil or magnets, the louder and clearer the sound is because there is a stronger vibration.

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